Internal principal consultant / Innovative, result driven global leader with 19+ yrs of broad based background in finance & banking, retail, energy, engineering, manufacturing & supply chain. Have excellent leadership ability to deal with all levels of organization including C-level executives & effectively build cross-functional consensus among key stakeholders to achieve desired results through change management. Recognized for cost reduction, organic growth, & ability to bring value to customer through strategy deployment & process/product transformation.
• Lean Sensei / TPS –Value, Flow, Pull, Perfection
• Kaizen / Teach & Mentor Lean, Six Sigma(1000+)
• Lean & Six Sigma (Certified Master Black Belt)
• Design for Lean & Six Sigma (DMAIC, DFSS)
• Transactional / office lean six sigma experience
• Hoshin Planning/ Change Management
• Enterprise wide Program / Project Mgt. (PMO)
• Global Best Practices / Benchmarking
• Business Process Management
• Innovation Strategies (TRIZ)/ Risk Mgt.
• Business Strategy / Planning / Model
• Financial / Simulation Modeling
• Balanced Scorecard / KPI, KRI, KCI Report Design
• IT – Technology Implementation (ERP/BPM/BRE)
• Front / Back Office Reorganization (BPO) / SCOR
• Capacity Planning / P & L responsibility
KEY ACCOMPLISHMENTS
• Reduced overtime 80% & savings of $ 7M by streamlining & automation of collateral and bond processes
using BPM/BRE at Wells Fargo.
• $ 100M PSCR reduction by optimizing the energy (power) trading mix – real-time, day-ahead, short-term,
long-term, & structured trading at DTE Energy resulted in $10/household
• Order to Cash 75% cycle time reduction & savings of $ 25M by redesigning End-to-End processes at Visteon.
EXPERIENCE
Hetke Consulting Inc., MI Sep.’09- Present
Independent Consultant on various Lean, Six Sigma and Benchmarking projects.
AVERY DENNISON – Retail Information Services, Framingham, MA Mar.’09 - Aug. ‘09
Global Enterprise Lean Sigma Champion Consultant /Global Business Processes / Operations (reported to sr. vice president operations) – Part of global resource reduction Sep ‘09
Led Hoshin Kanri along with C-level executives to develop global continuous process improvement strategy / implementation & managed 20 projects using enterprise project mgt. and managed global staff of 10 individuals.
• Increased speed & improved quality among regions by implementing global measurement system & SOP’s/SWI, sharing global best practices and communize the global processes across Retail Information Services. Expected savings of $ 10M .
• Achieved global product consistency & reduced the cost by redesigning End-to-End Global Supply Chain Process (procurement and sourcing) from decentralized process to hybrid process (Centralized – Global level
& Regional level and decentralized – site level). Expected savings of $ 5M.
• Expected Annual savings of $ 15M.
WELLS FARGO – Corporate Trust Services, Columbia, MD Jul ‘07 – Feb.‘09
Global Vice President / Process Excellence Consultant / Structured Finance (reported to sr. vice president operations) Worked with C-level executives to deploy continuous improvement strategy / implementation using Hoshin Planning & developed “Extended Value Stream mapping†to select, manage, & track top 40 projects to increase efficiency across Collateral and Bond processes using enterprise project mgt. Managed global staff of 15.
• Reduced loan accounting rejection-60% & cycle time-50% resulted in $ 6M savings by redesigning End-to-End process.
• Reduced bond processing rejection at first / second level inspection & cycle time reduction for processing bonds by 50% leading into savings of $ 5M.
• Generated savings of $ 1.5M by implementing Measurement System across entire Corporate Trust Services (RMBS, CMBS, ABS, CDO’s) to measure value added vs. non-value added activities across process & further sharing Best Practices across client teams.
• Generated 98% automated process & reduction of overtime by 8000 hrs/month & savings of $ 7M by developing ideal process using BPM (Lombardi Software), BRE (Pegasystems) & BI for- loan accounting, default, bond processing,
& loss tracking processes.
• Taught Lean Six Sigma Green/Black belt courses (20 BB, 50 GB, 200+ mentor/coach & conducted 50+ Kaizen)
• Annual savings of approx. $ 19.5M
DTE ENERGY- Energy Trading, Ann Arbor, MI Jun. ‘04 – Jul. ‘07
Operating System Manager / Deployment Consultant /Master Black Belt (reported to vice president operations)
Deployed & implemented Lean & Six Sigma strategy for Energy Trading, Generation Optimization & Distribution group, tracked/managed 60+ projects related to revenue growth & efficiency and managed staff of 8 individuals.
• Led to $ 50M revenue boost & optimized Energy (power) Trading Structure Transaction process.
• Resulted into $ 50M savings by developing/implementing performance center to monitor equipment reliability that led to better business transactions of sale/purchase of power.
• Resulted in $ 30M savings/yr by maximizing value of capital expenditure for long & short-term investment
& analyzed required return, led in more reliability & power transaction.
• Generated $ 25M saving & optimized bidding strategy for buy/sell of power using classical Design of Experiments in MISO (Power Mkt.).
• Reduced 50% cost in Generation optimization area using DFLS in collaboration with McKinsey & Co.
• Optimized natural gas distribution process(call center/customer service) led to 99% time commitment.
• Trained 50+ leaders, 60+ Black Belts, 200+ Green Belts, mentored/coached 1000+ individuals & conducted 70+ Kaizen for various Lean & Six Sigma projects.
• Annual utility bill reduction by approx. $10/ household.
VISTEON CORP.(Formerly Ford Motor) Corporate Strategy / Business Development / M&A ,MI 1997 - 2004
Corporate Strategy Deployment Leader / Black Belt – Finance, HR, Customer Service (reported to director corporate operations)Led Lean Six Sigma deployment, project selection for Corporate Strategy / Planning, Finance, Communication, Taxation, Government Affairs, Human Resources & Customer Business Group (CBG).
• Reduced number of defects by 80% that resulted in savings of $ 4.5M (soft savings/cost avoidance)
& improved the internal communication system process using Lean/DMAIC.
• Resulted in savings of $8 mil by increasing return on investment incentives from state & federal government. Increased incentives from 1% to 5%.
• Resulted in savings of $ 15M by optimizing link between Customer Business Groups (CBG) & Order to Cash.
• Managed & led Corporate "HOSHIN" breakthrough team.
• Annual savings of approx. $ 23M.
Global Corporate Strategy, Business Development, M&A Mgr (reported to director strategy)
Worked with senior management & board of directors to develop Corporate Strategy Process & Scenario Planning Studies to support Visteon’s business model.
• Led team along with investment bank & research institutions. Responsible for developing strategic intelligence, competitive profile, financial analysis & scenario planning studies for global business opportunities. This supported negotiation process for sell/buy/swap portfolio.
• Generated revenue of $ 2.8M by constructing business vision, strategy, planning, & forming Telematics
& Multimedia group.
• Directed Visteon towards development of hybrid vehicle components by constructing a business vision
& strategy for Visteon’s participation in hybrid electric vehicle.
• Led team to develop process/strategy to grow sales revenue of non-automotive related businesses including electronics.
• Developed Technology Implementation Plan to support selection & commercialization process of new technologies based on prioritization of business plan initiatives & future investment matrix. Commercialization process directed funds towards high growth technologies.
• Led formation of engineering development centers outside US & reduced engineering cost by $ 50M by working with senior management to develop business plan for divisions, regions to support Visteon Corporate Strategy for low cost engineering centers.
• Annual savings of approx. $ 50M
FORD MOTOR COMPANY Exterior Systems Design Engineering- Dearborn, MI 1989 – 1997
Senior Product Design Engineer - Exterior Systems and Electronics (reported to manager design)
Developed & implemented design for bumper technologies enhancing vehicle performance across product lines.
• Generated savings of $ 30M by developing knowledge based eng. (KBE) for front-end system.
• Increased occupant safety by redesigning front-end system to support 40% offset crash.
• Resulted in savings of $ 33M by designing & developing prototype of steel inserted blow molded front-end system to support intelligent transportation systems.
• Annual savings of approx. $ 63M.
Sr. Manufacturing Engineer (reported to manager manufacturing)
• Resulted in inventory savings of $ 5B by decreasing Order to Delivery (OTD) cycle time for vehicle across all assembly plants by improving End-to-End process with inside & outside suppliers to support vehicle sequence at Wixom Assembly Plant.
• Optimized vehicle assembly sequences process using discrete manufacturing simulation & presented results to senior management.
• Annual savings of $ 5B across all the assembly plants worldwide.
EDUCATION:
MS Industrial and Systems Engineering University of Michigan, MI.
MBA Finance / Operations Research University of Delhi - India
BS Manufacturing / Production Engineering Birla Institute of Technology- India
PROFESSIONAL DEVELOPMENT / CERTIFICATIONS:
A3, continuous flow, learning to see, seeing the whole, creating level pull, material flow – Lean Enterprise, 2009
Lean Training Wells Fargo, MD 2008
Project Management Training Wells Fargo, MD 2007
Lean Training/Cube innovation/Institute of Lean Innovation DTE Energy, MI. 2005
Certified Lean Six Sigma Master Black Belt - Int'l Quality Fed (IQF) Ford/Visteon MI. 2003-04
Certified Lean Six Sigma Black Belt - Six Sigma Academy Ford/Visteon MI. 2001-04
Quality Training Ford Motor, MI. 2000
Lean Transformation Training Ford Motor, MI. 1999
PATENTS, HONOR & PUBLICATIONS:
Patent: Light Truck Tailgate Assembly -1999 (Patent # 5,947,540) – Ford.
Patent: Steel Inserted Blow Molded Bumper System - 1997 (Patent # 5,658,027)- Ford.
Nominated for Ford Technology award for developing a "Knowledge Based System for bumpers" 1996.
Publication: Simulation of Transient Conjugate Heat Transfer to Improve "Door Trim Mfg" 1994.
Teaching Assistant-Taught Engineering Statistics classes at University of Michigan-Dearborn 1988-1989.
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